Alkaline resistant organic coatings for corrosion susceptible substrates III

ABSTRACT

Primers that are aqueous emulsions comprising (a) at least partially neutralized reaction product of di- or poly epoxy compounds and hydroxy amines made in water miscible solvents and (b) amino resin crosslinkers yield, upon curing, alkaline resistant coatings that provide corrosion protection even in absence of inhibiting pigments as chromates.

This is a continuation of application Ser. No. 938,670, filed Aug. 31,1978, now abandoned.

BACKGROUND OF THE INVENTION

This invention relates to preventing corrosion of susceptible substratesas ferrous metals and includes, in particular, resins that retardcorrosion of such substrates even when formulated in primer compositionsthat are free of such inhibiting pigments as chromates.

The corrosion of steel immersed in an aqueous environment can often beslowed to an acceptable rate by the introduction of corrosion inhibitorssoluble in the aqueous medium. In the case of steel structures subjectedintermittently to a corrosive environment, or under conditions whichpreclude effective incorporation of a corrosion inhibitor into thecorrosive medium, protective organic coatings are often used. One of themajor functions of these coatings is to act as a reservoir for sparinglysoluble inorganic corrosion inhibitors which act to slow the rate ofcorrosion at coating defects and other incipient anodic corrosion sites.Among the most effective inhibitors are inorganic chromates whose safetyhas been questioned by some. While the elimination of these pigments maytherefore be desirable, it is found that in the absence of effectivecorrosion inhibiting pigments extensive adhesion failure adjacent tocoating defects and flaws can take place, resulting ultimately in theuncontrolled spread of corrosion. The principal cause ofcorrosion-induced adhesion failure is generally thought to bedisplacement and/or degradation of the coating resin by cathodicallyproduced hydroxide ion. Corrosion inhibitors suppress this effect byslowing the overall rate of corrosion, limiting the amount of alkaliproduced. In the absence of corrosion inhibitors it is thereforenecessary that the coating resin be exceptionally resistant todisplacement and/or degradation by corrosion-produced hydroxide.

A principal objective is, therefore, the provision of resins suitablefor use in organic coatings and additionally highly resistant to alkalidegradation. A further objective is the provision of organic coatingformulations which enable ferrous substrates to be protected fromcorrosion without the incorporation of possibly deleterious corrosioninhibitive pigments. It is further desired that the organic coatings besuitable for use as primers on automotive steel substrates and that theapplication and handling characteristics, including shelf stability, becompatible with conventional commercial paint operations and practices.

THE INVENTION

This invention relates to compositions and methods that retard corrosionof susceptible substrates in the absence of conventional amounts ofinhibiting pigments as chromates and includes, especially, primercompositions adapted for use on automotive steels and other suchsubstrates. More particularly, this invention includes crosslinkingcompositions that cure into coatings on bare and treated steels andresist spread of corrosion, particularly from coating surface defects.

Briefly, the crosslinking compositions include (I) the reaction productof (a) epoxy reactant and (b) amine reactant, (II) amino resincrosslinking agent, and (III) optionally, a di- or polyhydroxy compound,wherein the amine reactant comprises secondary or primary and secondaryamine and, also, is mostly, on a molar basis, hydroxy amine. In analternative embodiment, (a) and (b) need not be fully reacted prior toapplication onto the substrate. Surprisingly such compositions may becured within commercially acceptable curing schedules withoutvolatilization of the amine to provide coatings that are exceptionallyresistant to degradation/displacement under corrosive conditions and mayadvantageously be cured at even lower temperatures in the presence ofcatalyst.

In one embodiment, the crosslinking compositions may be formulated intosolvent-based coatings as spray primers that exhibit corrosionresistance considerably in excess of certain conventional primers.Moreover, the crosslinking compositions may be formulated intowater-based primers that exhibit desirable properties.

In another embodiment, certain reactive catalysts have also been foundthat reduce cure temperature required for primers containing thecrosslinking compositions while maintaining and improving filmcharacteristics compared to usual catalysts.

The discovery that corrosion prevention may be accomplished in theabsence of inhibiting pigments provides an alternative means ofpreventing corrosion that is believed to utilize a mechanism differentthan when inhibiting pigments as chromates are included. Moreparticularly, available evidence indicates that cured coatings, asdescribed more fully herein, rather than slowing the overall rate ofcorrosion by retarding anodic dissolution of iron as a means to retardcorrosion, provide an adherent crosslinked network which isexceptionally resistant to degradation/displacement by cathodicallyproduced hydroxide and thus limit the total area over which thecorrosion reactions can occur.

DETAILED DESCRIPTION OF THE INVENTION

The essential components of crosslinking compositions of this inventioninclude certain epoxy compounds, hydroxy amines and amino resincrosslinking agent. The components are combined in a fashion that formsthe crosslinking composition useful in solvent-base and water-baseprimer coating compositions.

Compositional Ingredients (A) EPOXY-AMINE REACTION PRODUCT

The epoxy amine reaction product is formed in nonaqueous medium byreacting a di or polyepoxide (that is preferably free of carboxy ethermoieties linking the epoxide groups) with certain amines.

1. Epoxy Reactant--The epoxy reactant essentially should contain atleast about two, on the average, epoxy groups per molecule and maycontain three or more with a molecular weight preferably above about 300(number average) and up to about 10,000 or more, depending on factors asdesired viscosity and solids content.

One class of suitable epoxy compounds for the epoxy reactant includereaction products of di or polyhydric, mono, di or polycyclic compoundswith epihalohydrins of the formula ##STR1## wherein X is halogen aschloro and Y is hydrogen or lower alkyl such as methyl or ethyl whichepihalohydrin reaction products are exemplified by such straight chainepoxy terminated compounds containing glycidyl ether groups asbis-phenol A-epichlorohydrin reaction products that are commerciallyavailable as, for example, Epon 828, 1001 or 1004 (marketed by ShellChemical Company). Such products contain aromatic groups as benzenenuclei at a preferred average of at least about one, more preferably forthis invention at least about two, on the average, for each terminalepoxy group. Especially suitable are bis-phenol A-epichlorohydrinreaction products comprising in major amounts up to 10 or morebis-phenol moieties within the epichlorohydrin reaction productbackbone, e.g. molecular weights in a range of up to about 8000,preferably 700-6000, on a number average basis.

Other examples of epoxy compounds for the epoxy reactant includepolyepoxy compounds (averaging more than about two epoxy groups permolecule) which are also commercially available. In this group of epoxycompounds are the Novolac epoxy resins, e.g. Epon 152 and 154 (marketedby Shell Chemical Company). These polyepoxy resins include epoxidizedproducts of phenol formaldehyde resins that contain terminal glycidylether groups from aromatic moieties.

Aliphatic including cycloaliphatic epoxy compounds having, on theaverage, at least about two epoxy groups per molecule may also beemployed. Such aliphatic epoxy compounds include epihalohydrin andaliphatic di or polyols such as glycols reaction products, epoxidizedpolybutadienes, vinylcyclohexenedioxide and dipentene dioxide. Stillfurther, hydrogenated bis-phenol A epichlorohydrin products may also beemployed.

Compatible mixtures of any of these epoxy compounds are also suitable.

In one preferred embodiment, the epoxy reactant comprises relativelyhigh molecular weight (e.g. number average above about 700) epoxycompound that have hydrophobic groups (as epihalohydrin reactionproducts of a diol, e.g. bis phenol-A) for these have been found toadvantageously further provide enhanced moisture resistance to the curedcoatings as compared to lower molecular weight epoxy compounds made inthis way. Alternatively, as will be more fully described hereinafter,certain lower molecular weight epoxy compounds may be reacted withprimary and secondary alkanol amines to provide epoxy amine reactionproducts that similarly provide more desirable moisture resistance.Preferably, however, the epoxy reactant comprises higher molecularweight epoxy compounds as those bis-phenol A-epichlorohydrin reactionproducts that have at least about 25 mole percent (more preferably atleast about 75 mole percent) of compounds that have two or more, e.g.about 3-10 aromatic groups per epoxy group.

2. Amine Reactant--The amine reactant preferably comprises secondary orprimary and secondary amine desirably having a total of up to about 20carbons per amino nitrogen and with at least about 75 mole percent ofthe amine reactant comprising at least one hydroxy amine having one ormore (preferably two) primary hydroxy groups on carbon atoms that arenot adjacent to any amino nitrogen. Secondary amines are typicallysuitable with higher molecular weight epoxy compounds whereascombinations of primary and secondary amines are advantageous with lowermolecular weight epoxy compounds as the epoxy reactant so as to increasethe molecular weight of the epoxy amine reaction product. Secondarymono-amines are normally employed with polyepoxide having three or moreepoxy groups per molecule.

Hydroxy of the hydroxy amine serves as a moiety that is believed tochemically react with at least a portion of the amino resin crosslinkingagent during curing so as to provide a crosslinked coating; it ispreferred that the hydroxy amine have primary hydroxy attached toaliphatic carbon. Also, at least one amino nitrogen of the hydroxy amineis preferably substituted only by aliphatic carbon, i.e. hydroxyaliphatic amine, although the aliphatic carbon chain may be interruptedor substituted as with non-interferring heteroatoms as oxygen oraromatic as aryl or tertiary amine.

Hydroxy aliphatic secondary amines and, particularly hydroxy alkylsecondary monoamines are advantageous for the amine reactant in manyinstances, and especially desirable are hydroxy alkyl amines wherein thealkyl group is preferably lower alkyl e.g., up to 7 carbon atoms. In onepreferred embodiment, the amine reactant comprises all or nearly all(e.g. 90 mole percent or greater) secondary amine that is amino alcoholand especially amino alcohol bearing two hydroxy alkyl substituents as,for example, diethanol amine.

A class of preferred hydroxy amines are illustrated according to thefollowing formula: ##STR2## wherein R and R' are independently hydrogenor straight or branched chain aliphatic of up to about 10 carbons eachproviding that (a) at least one of R and R' is not hydrogen and (b) atleast one of R and R' is substituted by hydroxy on a primary carbon atomthat is not adjacent to any amino nitrogen. R and R' can also form partof a ring compound as a six membered ring. More preferably, R and R' areindependently alkyl and desirably up to 7 carbons each and especiallyfor water-base formulations hydroxy (primary) alkyl up to 4 carbonseach.

A variety of amines, however, may be suitably employed together as, forexample, primary and secondary amines which are mixtures of alkyl aminesand hydroxy alkyl amines. The important criterion is that there besufficient hydroxy functionality, especially primary hydroxy, in thereaction product of the amine reactant and epoxy reactant to insureadequate reaction with the amino resin crosslinking agent.

Preferably, however, about 90 or more mole percent of the amine reactantcomprises amino alcohols with primary hydroxy and especially hydroxyalkyl monoamine preferably bearing a primary hydroxy on both alkylgroups.

3. Reaction Conditions for Product of Epoxy Reactant and Amine Reactant

The epoxy and amine reactants are reacted at conditions that allowopening of the epoxy ring by amino nitrogen and provide a gell freereaction product. With secondary amines, this generally results intertiary amino groups whereas primary amines provide secondary aminogroups which may undergo further reaction with an unreacted epoxy of thesame or more probably of another molecule epoxy reactant resulting inchain extension.

The reaction medium comprises preferably nonaqueous medium that may beof diverse but preferably polar character and serves to maintain contactof reactants, control reaction speed, maintain desirable viscosity andother functions well known in the art. Thus, suitable solvents anddiluents for the reaction medium include aromatic and aliphatichydrocarbons, halides, ethers, alcohols, ketones such as methylamylketone, n-amyl ether, xylene, butanol, oxygenated solvents such aspropylene glycol monopropyl ether, cellosolves as 2-methoxy ethanol,2-butoxy ethanol, carbitols as ethoxy butoxy ethanol, and the likeincluding mixtures of these. Moreover, di- and polyhydroxy compounds, ashereinafter disclosed, may also serve as reaction medium or partthereof.

Elevated reaction temperatures may be employed to facilitate reactionbetween the epoxy reactant and amine reactant and the reaction may beconducted stepwise. The reaction is complete when the product issubstantially free of unreacted epoxy groups as nearly equivalentamounts (e.g. about 0.9-1.0 amine equivalents per 1 to 1.1 epoxyequivalent wherein an amine equivalent is one for a mole of secondarymonoamine and two for a mole of primary monoamine and mole of diepoxidecompound, for example, has two equivalents) are preferred. Thus, thereaction product of the epoxy reactant and amine reactant shouuldcontain less than 20% of the original unreacted epoxy groups, moredesirably less than 10% as 5% or less unreacted epoxy groups, based onthe number originally present.

(B) AMINO RESIN CROSSLINKING AGENT

The amino resin crosslinking agent may be admixed with the abovereaction product (A) at levels of about 5-30 weight percent of thecombined weight of (A) and optional ingredient (C) as hereinafterdescribed. Preferred amino resin crosslinking agent includes well knownand commercially available materials that are principally condensationproducts of amino or amido compounds with aldehydes which may bemodified by monohydric alcohols of normally up to about four carbons.

Especially preferred amino resin crosslinking agents are partiallyalkylated melamines (melamine formaldehyde resins modified by alcohols)e.g. partially methylated melamines and butylated melamines. Anotherpreferred cross-linking agent is urea formaldehyde condensate modifiedby alcohol as butylated urea resin. Mixtures of crosslinkers as mixturesof alkylated melamines and alkylated urea are found especially suitableas, for instance, in solvent base primers using butylated types atweight ratios of (a) butylated melamine resin to (b) butylated urearesin of a:b of between 1:1 to 10:1.

Other suitable crosslinkers that are amino resins include glycol urilresins and benzoguanimine resin.

(C) OPTIONAL INGREDIENTS

Di- and polyhydroxy compounds of diverse character may be employed tomodify film properties as well as acting as solvent including reactivesolvent for solubilizing the crosslinking compositions. These compoundscan also impart increased flexibility as well as reducing cratering inspray primers formulated with (A) and (B) above.

A preferred class of hydroxy compounds include aliphatic di hydroxycompounds, especially glycols and glycol ethers of the formula HO--C_(a)H_(2a) O)_(x) (C_(b) H_(2b) O)_(y) H wherein a, b, x and y areindependent integers and a and b are from 2 to 6 and x and y are from0-10 with the sum of x and y being from 1 to 10. Examples includeethylene glycol, dipropylene glycol, and 1,6 hexanediol. Another classof glycols include hydroxy terminated polybutadienes, hydrogenatedbis-phenol-A, such hydroxy compounds being of generally hydrophobiccharacter and molecular weights of about preferably 100-5000, numberaverage. Higher boiling solvents (e.g. boiling point above about 180° C.as 190°-250°) that are of polar character tend to interact with thecrosslinking composition and thereby allow higher solids content.

Pigments may be used in the primer compositions of this invention inaccordance with usual technique except, if desired, chromate pigmentsneed not be included to get good corrosion resistance. Exemplarypigments include titanium dioxide, silica, carbon black, and barytes andare employed at pigment: binder (i.e. sum of (A) and (B) above) weightratios of about 40:60-60:40. Other ingredients as solvents, diluents,surfactants, catalysts and the like may also be included for theirrespective functions.

Catalysts and especially acid catalysts may be used to accelerate cureof the primer compositions herein as by lowering cure temperaturesrequired to effect crosslinking within a 15-30 minute bake cycle fromabout 180° C. to 140° or even less. Acid catalyst include protic orLewis acid materials preferably at about 0.5-5.0% by weight of theprimer composition and typical acids include strong acids such asphosphoric acid, paratoluene sulfonic acid, and substituted boroncompounds as trialkoxy boron compounds, although, however, certain ofthese materials may result in films which exhibit less than desiredmoisture resistance.

An especially preferred catalyst for crosslinking compositions hereincomprises reactive hydroxy (preferably aliphatic) phosphate esters madeby reacting P₂ O₅ and di or triol. This catalyst, employed preferablybetween about 0.1-5% by weight of the combined weight of (A) epoxy aminereaction product and (B) amino resin crosslinking agent provides notonly reduced cure temperature but also, as distinguished from otherusual strong catalysts advantageously does not increase moisturesensitivity in certain formulations, particularly solvent based primersand can also lead to improved corrosion resistance in water base primersas spray primers. The reactive phosphate comprises a hydroxy functionalorganophosphate which is present in the composition as a mono- ordiester or as a mixture of such mono- and diesters. The hydroxyfunctional organophosphate esters useful in the composition of theinvention include those having the formula: ##STR3## wherein n=1 to 2and R is hydroxy substituted hydrocarbon, preferably selected from thegroup consisting of mono- or dihydroxy alkyl, cycloalkyl, or arylradicals. Preferably the alkyl, cycloalkyl, or aryl radicals contain 3to 10 carbon atoms, and especially desirable are aliphatic orcycloaliphates radicals substituted by hydroxy, optionally interruptedby heteroatoms as oxy as well as aryl.

Among the numerous suitable mono- or dihydroxy functional radicals are:2-ethyl-3-hydroxyhexyl; 4-methylolcyclohexylmethyl; 2,2diethyl-3-hydroxypropyl; 8-hydroxyoctyl; 6-hydroxyhexyl;2,2-dimethyl-3-hydroxy-propyl; 2-ethyl-2-methyl-3-hydroxypropyl;7-hydroxyheptyl; 5-hydroxypentyl; 4-methylolbenzyl; 3-hydroxyphenyl; 2,3dihydroxypropyl; 5,6 dihydroxyhexyl; 2-(3-hydroxycyclohexyl)-2-hydroxyethyl; and 2-(3-hydroxypentyl)-2-hydroxyethyl.

The above radicals are intended to be only exemplary and numerous otherradicals falling within the defined scope of the organophosphate estersuseful in the compositions of the invention will be apparent to thoseskilled in the art. Among the most preferred radicals are mono- ordihydroxy functional alkyl radicals containing 3 to 10 carbon atoms.

A preferred method for preparing the hydroxy functional organophosphateesters useful in the compositions of the invention is by anesterification reaction between an excess of an alkyl, cycloalkyl oraryl diol or triol or mixture thereof and phosphorus pentoxide. When atriol is used as a reactant, preferably at least one of the hydroxylgroups should be secondary. The reaction between the diol or triol andthe phosphorus pentoxide is generally carried out by adding phosphoruspentoxide portionwise to an excess of diol or triol in a liquid state orin solution in a suitable solvent. A preferred temperature for carryingout the reaction is between about 50° C. and about 60° C. Due to themultiple hydroxy functionality of the diol or triol reactant, minoramounts of polymeric acid phosphate as well as certain cyclophosphatesare also generated during the reaction. These polymeric and cyclicmaterials also serve as a reactive catalyst and, therefore, need not beseparated from the hydroxyphosphate esters described above. It isadvantageous in preferred embodiments of the invention to employ allreaction products, i.e., the hydroxy functional organophosphate estersand the minor amount of polymeric acid phosphate cyclophosphates, aswell as excess diol or triol in the crosslinking compositions. Excessdiol or triol may serve in those compositions as all or a portion of theoptional hydroxy functional additive. Reactive catalysts prepared by theabove preferred method will generally include about a 1 to 1 ratio ofthe mono- and diester organophosphate.

Still another preferred method of preparing the hydroxy functionalorganophosphate esters useful in compositions of the invention is by anesterification reaction between phosphoric acid and an alkyl, cycloalkylor arylmonoepoxide. This reaction is carried out by adding between about1 and about 2 moles, preferably between about 1 and about 1.5 moles, ofthe monoepoxy material to 1 mole of phosphoric acid or its solution in asuitable solvent. During the esterification reaction which occurs, ahydroxyl group is formed. If a dihydroxy radical is desired in theorganophosphate ester, a monoepoxide bearing hydroxy functionality maybe used as a reactant. Preferred monoepoxide materials useful in thismethod are well known monoepoxides selected from monoepoxy ethers,monoepoxy esters and alkylene oxides. Exemplary of preferredmonoepoxides for use in this esterification reaction are: propyleneoxide, butylene oxide, cyclohexene oxide, styrene oxide, n-butylglycidylether and ethylglycidyl ether. As will be understood by these skilled inthe art, the proportion of monoester and diester formed by the reactionwill vary with the selected molar ratio of the monoepoxide and thephosphoric acid. When 1 mole of monoepoxide is used, per mole ofphosphoric acid primarily monoester is formed while a molar ratio of 2to 1 results in primarily diester. A molar ratio of 1.5 to 1 will resultin an approximately 1 to 1 mixture of mono- and diesters. In all cases aminor amount of the triester will be formed. While this triesterobviously will not serve as a reactive catalyst, it will crosslink withthe amino crosslinking agent of the composition and, thus, may be safelyincluded.

The hydroxy functional organophosphate ester component of thecrosslinking composition of the invention is a reactive catalyst whichallows the composition to cure rapidly at a low temperature. The acidfunctionality of the mono- or diester or mixture of such esters reactswith the hydroxy reactive functionality e.g., amino resin crosslinkingagent so as to include the reactive phosphate in the crosslinked networkthereby not deleteriously effecting moisture resistance and, in somecases, improving corrosion resistance.

Primer Formulation

The crosslinking compositions comprising epoxy reactant and aminereactant reaction product, amino resin crosslinking agent and optionallydi or polyhydroxy compound may be formulated into a variety of primerformulations including those based on non-aqueous medium and water basemedium. Such primers may be used as coatings for bare and treated steels(conversion coated with phosphates) as well as guide coats overpreviously deposited primers applied as by electrodeposition.Conventional modifying ingredients may be used in the primerformulations including, for example, flow control agents, pigmentdispersants, thixotropes, anti-cratering aids, photostabilizers and thelike.

1. Solvent Base Primers

Solvent base primers exhibit good thermal and shelf stability and may beapplied to metal substrates according to usual techniques as by spray,curtain, dip and other such coating methods.

2. Water Base Primers

Water base primers may be formulated from the crosslinking compositionsas hereinbefore and hereinafter described. These water-based primers aremade with at least partially neutralized epoxy amine reaction products.The amino resin crosslinking agent is selected from water soluble anddispersible agents as also described and employed at similar levels. Thewater-based primers may be applied as spray primers and also can beelectrodeposited. (See commonly assigned U.S. Ser. No. 938,673, filedAug. 31, 1978 in name of Robert Wingfield, now U.S. Patent for 192,929.

Water-based spray primers are advantageously prepared in watercompatible solvents and diluents as ethylene glycols and alkylatedglycols, e.g. oxygenated solvents as cellosolves and carbitols andthereafter at least partially neutralized by acid, particularly weakorganic acid as formic, acetic or butryric acid. Coupling agents may beadvantageously employed.

Water-based spray primers can be formulated with high levels of watere.g., greater than 10% as about 30-50% by weight and yet cure withinconventional conditions as 180° C. for 20-30 minutes and even less withcertain catalyst as reactive hydroxy phosphate catalyst as herebeforeand hereinafter described.

It is found that particularly advantageous waterbase spray primers maybe formulated as stable emulsions when epoxy and amine reactants arereacted in water miscible solvent and the amine reactant comprises oneor more water soluble amino alcohol up about 20 carbons, especiallywater soluble hydroxy alkyl amines, particularly secondary aminescontaining at least two primary hydroxy groups as diethanol amine anddipropanolamine.

Especially suitable water miscible solvents (water miscible as usedherein means the solvent forms at 25° C. a continuous phase with waterwhen at 20% by weight of water or more) include as examples monohydroxyethers as C₁ -C₆ etherified glycols as R(OCx)_(y) OH wherein R is alkylfrom 1-8 carbons and x is 2-4 and y is 1-10 and particularly those whichhave boiling points below about 180° C., e.g., 2-methoxy ethanol,2-ethoxy ethanol, and propylene glycol monopropyl ether. Other suitablesolvents include ethanol, propanol, isopropanol and the like. Higherboiling e.g. above about 180° C. glycols may also be used as co-reactivesolvents.

In a convenient method of making, a concentrate is made from reactingepoxy reactant and amine reactant in water miscible solvent andthereafter at least partially neutralizing with weak organic acid of upto 4 carbons as formic, acetic or oxalic acid in the presence of aminoresin cross-linking agent to form a concentrate that may be thereafterreadily dispersed in water for spraying.

Moreover, partially methylated or butylated melamine resins arepreferred. Conventional pigment dispersants and other additivesincluding silanes and organotitanates may also be employed.

3. Alternative Embodiment--Multicomponent Coating Composition

The epoxy and amine reactants along with the amino resin crosslinkingagent and, preferably, di or polyhydroxy compound, all as abovedescribed, may alternatively be reacted together on the substrate to becoated. Thus, in this embodiment the epoxy and amine reactants anddesirably di or polyhydroxy compound (preferably having boiling pointsin excess of about 200° C.) are intimately admixed and applied to thesubstrate to be coated and cured thereon. In this embodiment, however,the amino reactant can also comprise solely primary amine that is ahydroxy amine. The primary amine, however, is normally employed withdi-epoxides.

Preferred primary amine, for this embodiment, that contain primaryhydroxy are hydroxy lower alkyl amines as ethanol amine, propanolamine,pentanol amine and the like. If secondary amines that are hydroxy aminesare employed, then such amines are preferably also lower hydroxyaliphatic amines as dialkanol amines containing up to 7 carbon atoms,e.g. diethanolamine or as lower alkyl hydroxy alkyl amines as2-(methylamino)-ethanol.

In this embodiment, it is important for corrosion resistance propertiesthat primer formulations are admixed shortly, e.g. within less than afew hours of but desirably greater than one half hour before applicationand cure. Advantageously, uncatalyzed multicomponent crosslinkingcompositions may be cured within conventional curing schedules and, ifdesired, be accelerated by catalyst. On the other hand, it is importantthat the amino resin crosslinking agent and epoxy reactant not bepermitted to stand for an undue length of time (e.g. several weeks)prior to formulation with the amine reactant comprising primary amineand application to the substrate. Preferably, the multicomponent systemis applied to substrates between about 30-600 minutes after mixing.

As mentioned, this alternative multicomponent embodiment preferably alsoutilizes di- or polyhydroxy compound such that, for example, the di- orpolyhydroxy compound advantageously serves as reactive solvent whichallows crosslinking compositions and ultimate coating compositions asprimers which have high solids content. Moreover, film properties asflexibility may be enhanced through incorporation of the di- orpolyhydroxy compound. In this regard, glycols of the formula HO--C_(a)H_(2a) 0)_(x) (C_(b) H_(2b) O--_(y) H wherein a and b are independently2-6 and x and y are independently 2-10 wherein the sum of x and y is2-10 are preferably employed.

The alternative multicomponent coating composition advantageously may beformulated into solvent base primer which may be applied in a variety ofways to the substrate as, for example, through dip, spray, curtain andlike coatings.

The following examples are intended as illustrating some of the morepreferred aspects and, accordingly, should not be considered asnecessarily limiting the scope of invention. All degrees are in degreesCelsius and parts in parts by weight unless specified otherwise.

EXAMPLE I

A heat curable coating composition suitable for automotive applicationis prepared from a bis-phenol A-epichlorohydrin epoxy resin,alkanolamine, and an amino resin crosslinking agent in the mannerhereinafter set forth:

    ______________________________________                                        Part A                                                                        Preparation of epoxy-alkonalamine resin                                       Materials       Parts by Weight                                               ______________________________________                                        Epon 1004.sup.(1)                                                                             625                                                           Diethanolamine   70                                                           Methyl amyl ketone                                                                            625                                                           Butanol         200                                                           Reactor Charge                                                                Diethanolamine   70                                                           Methyl amyl ketone                                                                            625                                                           ______________________________________                                         .sup.(1) A product of Shell Chemical Company, which is a reaction product     of epichlorohydrin and bis phenolA and described such as being a solid        with melting point 95-105° C.; GardnerHoldt viscosity at 25.degree     C. of QU(40% w soln in butyl Dioxitol®)Epoxide Equivalent 875-1000        (grams resin per gramequivalent of epoxide; Equivalent Weight (grams resi     to esterify one mole acid) 175. (Data Sheet SC:6958).                    

The reactor charge is heated to 70°-80° C. in a reaction vessel equippedwith a stirrer, reflux condenser, and thermometer. The Epon 1004 isadded over a four hour period. The temperature is maintained at 70°-80°C. throughout the addition of the epoxy resin and for four hoursthereafter. The epoxy-alkanolamine resin so formed is then cooled to 50°C. and diluted with butanol. The resin is then cooled to roomtemperature, filtered and formulated into a primer as hereinafterdescribed.

    ______________________________________                                        Part B                                                                        Formulation of Primer                                                         Materials              Parts by Weight                                        ______________________________________                                        Butylated melamine resin (RN 602).sup.(2)                                                            46                                                     Urea resin (RN 512).sup.(3)                                                                          6.7                                                    Titanium dioxide pigment                                                                             15                                                     Carbon black pigment   15                                                     Silica pigment         11                                                     Barytes pigment        102                                                    Xylene                 50                                                     Epoxy-alkanolamine resin from part A                                                                 399                                                    ______________________________________                                         .sup.(2) Product of Mobil Chemical Company that is described as being         butylated melamine formaldehyde resin with viscosity of VX; 58%               nonvolatiles; Acid number 2 maximum; solvent nbutanol.                        .sup.(3) Product of Mobil Chemical Company that is described as being         butylated urea formaldehyde resin; viscosity WY; nonvolatiles 50% ± 2%     Acid number 3.5-4.5; Color Gardner/max.; Solvent 80% nbutanol and 20%         ethylbenzene.                                                            

An unpigmented primer is prepared by dissolving the epoxyalkanolamineresin, the butylated melamine and the urea resin in xylene and butanol.A mill base is then prepared using one-third of the unpigmented resinand the pigments shown above. The remaining unpigmented primer is thenadded and thoroughly dispersed with the mill base. The resulting fullyformulated primer is filtered, applied to cold rolled, unphosphatedsteel panels by spraying and cured at 180° C. for 20 minutes. The curedcoating displays excellent corrosion resistance in salt spray, goodsolvent resistance to xylene and good flexibility and hardness.

EXAMPLE II

The procedures of Example I are repeated with the following difference:Epon 1001(1) replaces Epon 1004. All other materials used in preparingthe epoxy-alkanolamine resin and the fully formulated primer are thesame in kind and quantity as in Example I.

    ______________________________________                                        Materials     Parts by Weight                                                 ______________________________________                                        Epon 1001.sup.(1)                                                                           334                                                             ______________________________________                                         .sup.(1) Product of Shell Chemical Company which is described as a solid      and having viscosity (Gardner Holdt) DG, 1.0-1.7 poises (ASTMD445) in 40%     w soln. butyl Dioxitol®; and Epoxide equivalent 450-550.             

Unphosphated steel panels coated with the fully formulated primerdisplay excellent corrosion resistance to salt spray, good xylenesolvent resistance, flexibility and hardness.

EXAMPLE III

The procedures of Example I are repeated with the following difference:Epon 828 replaces Epon 1004. All other materials used in preparing theepoxy-alkanolamine resin and the fully formulated primer are the same inkind and quantity as in Example I.

    ______________________________________                                        Materials     Parts by Weight                                                 ______________________________________                                        Epon 828.sup.(1)                                                                            126                                                             ______________________________________                                         .sup.(1) Product of Shell Chemical Company which is described as a liquid     and having a viscosity (ASTM D445) 110-150; Epoxide equivalent 185-192;       Gardner Color 3 max; lbs./gal. (68° C.) 9.7.                      

Unphosphated steel panels coated with the fully formulated primerdisplay excellent corrosion resistance to salt spray, good xylenesolvent resistance, flexibility and hardness. Some sensitivity tocondensing humidity is also observed.

EXAMPLE IV

The procedures of Example I are repeated with the following difference:Diethanolamine is replaced by 2-(methylamino) ethanol. All othermaterials used in preparing the epoxy-alkanolamine resin and the fullyformulated primer are the same in kind and quantity as in Example I.

    ______________________________________                                        Materials         Parts by Weight                                             ______________________________________                                        2-(methylamino) ethanol                                                                         49                                                          ______________________________________                                    

Unphosphated steel panels coated with the full formulated primer displayexcellent corrosion resistance to salt spray, good xylene solventresistance, flexibility and hardness.

EXAMPLE V

A heat curable coating composition suitable for automotive applicationis prepared from an epoxy-alkanolamine resin, and an amino resincrosslinking agent. The epoxy-alkanolamine resin in this case is thecondensation product between lower molecular weight bis phenol Aepichlorohydrin epoxy resins and mixtures of primary and secondaryalkanoalamines. Resin preparation and primer formulation proceeds in themanner hereinafter set forth:

    ______________________________________                                        Part A                                                                        Preparation of epoxy-alkanolamine resin                                       Materials       Parts by Weight                                               ______________________________________                                        Epon 828.sup.(1)                                                                              190                                                           Diethanolamine  52                                                            Ethanolamine    15                                                            Methyl amyl ketone                                                                            200                                                           Butanol         75                                                            Reactor Charge                                                                Diethanolamine  52                                                            Ethanolamine     5                                                            Methyl amyl ketone                                                                            200                                                           ______________________________________                                         .sup.(1) A product of Shell Chemical Company, see Example III.           

The reactor charge is heated to 70°-80° C. in a reaction vessel equippedwith a stirrer, reflux condenser and thermometer. The Epon 828 is addedover a one hour period. The temperature is maintained at 70°-80° C.throughout the addition of the epoxy resin and for one hour thereafter.The remaining portion of ethanol amine is then added and the reaction ismaintained at 70°-80° C. for an additional one hour. Theepoxy-alkanolamine resin so formed is cooled to 50° C. and then dilutedwith butanol. The resin is cooled to room temperature, filtered andformulated into a primer as hereinafter described.

    ______________________________________                                        Part B                                                                        Formulation of Primer                                                         Materials              Parts by Weight                                        ______________________________________                                        Epoxy-alkanolamine resin from part A                                                                 532                                                    Butylated melamine resin (RN602).sup.(2)                                                             69                                                     Urea resin (RN512).sup.(3)                                                                           10                                                     Titanium dioxide pigment                                                                             23                                                     Carbon black pigment   23                                                     Silica                 16                                                     Barytes                153                                                    Xylene                 75                                                     Butanol                113                                                    ______________________________________                                         .sup.(2),(3) Products of Mobil Chemical Company, see Example I.          

The procedure for the pigmentation of the primer is the identical to theone employed in Example IB.

EXAMPLE VI

A heat curable coating composition suitable for automotive applicationis prepared from a bis phenol A-epichlorohydrin epoxy resin, analkanolamine, an amino resin crosslinking agent and glycol in the mannerhereinafter set forth:

    ______________________________________                                        Primer Formulation                                                            Materials             Parts by Weight                                         ______________________________________                                        Epoxy-alkanolamine resin from                                                                       399                                                     Example Ia                                                                    Butylated melamine resin (RN602).sup.(1)                                                            80                                                      Urea resin (RN512).sup.(2)                                                                          10                                                      Triethylene glycol    40                                                      Methyl amyl ketone    100                                                     Butanol               100                                                     Titanium dioxide pigment                                                                            15                                                      Carbon black pigment  15                                                      Silica pigment        11                                                      Barytes pigment       102                                                     ______________________________________                                         .sup.(1) See Example I, product of Mobil Chemical Company.                    .sup.(2) See Example I, product of Mobil Chemical Company.               

The unpigmented primer is prepared by dissolving the epoxyalkanolamineresin, the butylated melamine resin, the urea resin and the triethyleneglycol in xylene and butanol. The primer is pigmented in the mannerdescribed in Example Ib. The fully formulated primer is filtered,applied to cold rolled, unphosphated steel panels and cured at 180° C.for 20 minutes. The coating displays satisfactory corrosion resistancein salt spray.

EXAMPLE VII

The procedures of Example VI are repeated with the following difference:hydrogenated bis phenol A is substituted for the triethylene glycol. Allother materials in preparing the fully formulated primer are the same inkind and quantity as in Example VI.

    ______________________________________                                        Materials          Parts by Weight                                            ______________________________________                                        Hydrogenated bis-phenol A                                                                        20                                                         ______________________________________                                    

Unphosphated steel panels coated with the fully formulated primerdisplay excellent corrosion resistance, flexibility and hardness.

EXAMPLE VIII

The procedures of Example VI are repeated with the following difference:Poly bd R-45HT, a hydroxy terminated poly butadiene resin, issubstituted for the triethylene glycol. All other materials used inpreparing the fully formulated primer are the same in kind and quantityas in Example VI.

    ______________________________________                                        Materials       Parts by Weight                                               ______________________________________                                        Poly bd R-45HT.sup.(1)                                                                        20                                                            ______________________________________                                         .sup.(1) a product of ARCO/Chemical company, division of Atlantic             Richfield Company.                                                       

Unphosphated steel panels coated with the fully formulated primerdisplay excellent corrosion resistance, flexibility and hardness.

EXAMPLE IX

(a) Heat curable coating compositions suitable for automotiveapplication are prepared in the manner discussed in Examples I-VIII withthe exception that from 2.5% by weight of phosphoric acid is added tothe primer. The inclusion of small amounts of acid catalyst lowers thecure temperature.

(b) A heat curable coating composition suitable for automotiveapplication is prepared from a bis-phenol-A-epichlorohydrin epoxy resin,alkanolamine, and an amino resin crosslinking agent in the mannerhereinafter set forth:

    ______________________________________                                        Part A                                                                        Preparation of Epoxy-alkanolamine Resin                                       Materials       Parts by Weight                                               ______________________________________                                        Epon 1004.sup.(1)                                                                             625                                                           Diethanolamine   70                                                           Methylamyl ketone                                                                             625                                                           Butanol         200                                                           Reactor Charge                                                                Diethanolamine   70                                                           Methyl amyl ketone                                                                            625                                                           ______________________________________                                         .sup.(1) Product of Shell Chemical Company, see Example I.               

The reactor charge is heated to 70°-80° C. in a reaction vessel equippedwith a stirrer, reflux condenser, and thermometer. The Epon 1004 isadded over a four hour period. The temperature is maintained at 70°-80°C. throughout the addition of the epoxy resin and for four hoursthereafter. The epoxy-alkanolamine resin so formed is then cooled to 50°C. and diluted with butanol. The resin is then cooled to roomtemperature, filtered and formulated into a primer as hereinafterdescribed.

    ______________________________________                                        Part B                                                                        Formulation of Primer                                                         Materials              Parts by Weight                                        ______________________________________                                        Epoxy-alkanolamine resin from part A                                                                 39.9                                                   Butylated melamine resin (RN602).sup.(2)                                                             4.6                                                    Urea resin (RN512).sup.(3)                                                                           0.67                                                   Titanium dioxide pigment                                                                             15                                                     C-Black pigment        15                                                     Silica pigment         11                                                     Barytes pigment        102                                                    Xylene                 50                                                     Butanol                75                                                     Reaction product of 2-ethyl-1,3-                                              hexandiol with P.sub.2 O.sub.5 (1% based on resin                             solids).sup.(4)        0.23                                                   ______________________________________                                         .sup.(2),(3) Products of Mobil Chemical Company, see Example I.               .sup.(4) Prepared as follows:                                                 In a threenecked round bottom flask equipped with a stirrer dropping          funnel and a thermometer are placed 2500 grams of dry (dried over             molecular sieves) 2ethyl-1,3-hexandiol. Phosphorus pentoxide (450 grams)      is added portionwise with continuous stirring and an exothermic reaction      occurs. The addition of phosphorus pentoxide is regulated to maintain the     temperature at 50° C. After the addition is complete, the reaction     mixture is stirred at 50° C. for one more hour and then filtered.      The acid equivalent weight by titration with medium hydroxide solution is     found to be 357.                                                         

An unpigmented primer is prepared by dissolving the epoxy-alkanolamineresin, the butylated melamine, the urea resin, and the reaction productof 2-ethyl-1,3-hexanediol with P₂ O₅, in the butanol and xylene. A millbase is then prepared using one-third of the unpigmented primer and thepigments shown above. The remaining clear primer is then added andthoroughly dispersed with the mill base. The resulting fully formulatedprimer is filtered, applied to cold rolled, unphosphated steel panels byspraying and cured at 140° C. for 20 min. The cured coating displaysexcellent corrosion resistance in salt spray, good xylene solventresistance, flexibility and hardness.

EXAMPLE X

This example illustrates the epoxy resins containing ester functionalityshould be avoided in preparing epoxy alkanolamine resins. In thisexample poor corrosion resistance of a primer coating is observed whenAraldite Cy 179 is incorporated into the formulation.

    ______________________________________                                        Part A                                                                        Preparation of epoxy-alkanolamine resin                                       Materials       Parts by Weight                                               ______________________________________                                        Araldite Cy179.sup.(1)                                                                        126                                                           Diethanolamine  105                                                           Butanol         130                                                           Reactor Charge                                                                Diethanolamine  105                                                           Butanol         100                                                           ______________________________________                                         .sup.(1) A product of CibaGeigy Corp., an esterlinked diepoxide.         

The reactor charge is heated to 70°-80° in a reaction vessel equippedwith a stirrer, reflux condenser and thermometer. A solution of theAraldite Cy179 in 30 parts of butanol is added dropwise. The temperatureis maintained at 70°-80° C. during the addition and for 20 hoursthereafter. The resin is then cooled and formulated into a primer ashereinafter described.

    ______________________________________                                        Primer Formulation                                                            Materials             Parts by Weight                                         ______________________________________                                        Epoxy-alkanolamine resin from                                                                       67                                                      X, Part A                                                                     Butylated melamine resin (RN602).sup.(2)                                                            39                                                      Triethylene glycol    19                                                      Ferric oxide pigment  4                                                       Titanium dioxide pigment                                                                            4                                                       Silica                3                                                       Barytes               29                                                      Butyl Acetate         15                                                      Xylene                15                                                      ______________________________________                                         .sup.(2) See Example I, a product of Mobil Chemical Company.             

The unpigmented primer is prepared by dissolving the epoxyalkanolamineresin, the butylated melamine and the triethylene glycol in butylacetate and xylene. The primer is pigmented in the manner described inExample Ia. The fully formulated primer is filtered, applied to coldrolled, unphosphated steel and cured at 180° C. for 20 minutes. Coatingsobtained from this primer display very poor corrosion resistance.

Table of Results

Set forth below in the Table are results obtained relative to certain ofthe above Examples. The tests conducted are standard laboratory teststhat are intended to determine properties of primer coatings. The testprocedures are as follows: 24 hour salt spray test ASTMB 117-62, 64 SaltSpray Test; 10 day salt spray ASTMB 117-62, 64 Salt Spray Test for 240hours; condensing humidity test combined ASTMD 2246 and 2247 combinedhumidity testing under continuous condensing humidity; cathodic alkalineresistance test as described by A. G. Smith and R. A. Dickie, Ind. Eng.Chem., Prod. Res. Dev., 17(1), 45 (1978), a test in which the resistanceof the coating to displacement/degradation by cathodically producedhydroxide is evaluated.

    ______________________________________                                             Epoxy                                                                         Ester                                                                         Primer                                                                   Test .sup.(1)                                                                              Ex. I  Ex. II                                                                              Ex. III                                                                             Ex. IV                                                                              Ex. VII                                                                              Ex. X                            ______________________________________                                        A    3.sup.(2)                                                                             10     10    10    7.sup.(2)                                                                           10     0.sup.(2)                        B    --      9      8     NA.sup.(3)                                                                          --    9      --                               C    10      9      7     2     NA.sup.(3)                                                                          8      9                                D    3       10     10    10    9     10     0                                ______________________________________                                         A is 24 Hour Salt Spray Test.                                                 B is 10 Day Salt Spray Test.                                                  C is Condensing Humidity (10 day exposure).                                   D is Cathodic Alkaline Resistance (8 hour exposure).                          0-2  Total delamination or swelling of coating                                3-5  Significant loss from the scribe line, or serious blushing or            blistering of coating                                                         6-8  Little or no adhesion loss from the scribe line, but some minor          amount of nonscribe failure; also slight blushing                             9-10  No or very slight adhesion loss                                         .sup.(1) Tall oil modified, epon 828 epoxy ester primer which has been        crosslinked with a melamine formaldehyde resin.                               .sup.(2) Test discontinued at this point.                                     .sup.(3) Not available.                                                  

EXAMPLE XI

A multicomponent, heat curable coating composition suitable forautomotive application is prepared from a bis phenol A-epichlorohydrinepoxy resin, alkanolamine, a glycol, and an amino resin crosslinkingagent in the manner hereinafter set forth:

    ______________________________________                                        Part A                                                                        Preparation of Unpigmented Primer Formulation                                 Materials         Parts by Weight                                             ______________________________________                                        Epon 828.sup.(1)  34                                                          Ethanolamine      12.2                                                        Triethylene Glycol                                                                              19.4                                                        Butylated melamine resin.sup.(2)                                                                39                                                          Xylene            30                                                          ______________________________________                                         .sup.(1) See Example III, a product of Shell Chemical Company                 .sup.(2) See Example I, a product of Mobil Chemical Company              

An unpigmented primer is prepared by dissolving the epoxy resin, theethanolamine, the triethylene glycol and the butylated melamine resin isxylene. The mixture is thoroughly stirred for 45 min. during which timea slight temperature increase is observed. The primer is then applied tocold rollod, unphosphated steel panels by spraying and cured at 180° C.for 20 minutes. The cured coating displays excellent corrosionresistance in salt spray, good solvent resistance to xylene and goodflexibility and hardness.

    ______________________________________                                        Part B                                                                        Preparation of Fully Formulated Primer                                        Materials              Parts by Weight                                        ______________________________________                                        Unpigmented primer formulation from                                                                  134.6                                                  Part A                                                                        Titanium Dioxide pigment                                                                             4.1                                                    Ferric Oxide pigment   4.1                                                    Silica pigment         2.7                                                    Barytes pigment        28.6                                                   ______________________________________                                    

The freshly prepared unpigmented primer solution from part A isimmediately combined with the titanium dioxide, the ferric oxide, thesilica, the barytes. The pigment is dispersed; the fully formulatedprimer is then filtered, and immediately applied to cold rolled,unphosphated steel panels by spraying. After curing at 180° C. for 20minutes, the coating displays excellent corrosion resistance in saltspray and good solvent resistance.

EXAMPLE XII

The procedures of Example XI are repeated with the following difference:2-(methyl amino)-ethanol replaces the ethanolamine. All other materialsused in preparing the unpigmented primer and the fully formulated primerare the same in kind and quantity as in Example XI.

    ______________________________________                                        Materials         Parts by Weight                                             ______________________________________                                        2-(methyl amino)-ethanol                                                                        15                                                          ______________________________________                                    

Unphosphated steel panels coated with the fully formulated primerdisplay excellent corrosion resistance good xylene solvent resistanceand flexibility.

EXAMPLE XIII

The procedures of Example XI are repeated with the following difference:3-amino propanol replaces the ethanol amine. All other materials used inpreparing the unpigmented primer and the fully formulated primer are thesame in kind and quantity as in Example XI.

    ______________________________________                                        Materials       Parts by Weight                                               ______________________________________                                        3-amino propanol                                                                              7.5                                                           ______________________________________                                    

Unphosphated steel panels coated with the fully formulated primerdisplay excellent corrosion resistance good xylene solvent resistanceand flexibility.

EXAMPLE XIV

The procedures of Example XI are repeated with the following difference:Epon 1001 replaces Epon 828. All other materials used in preparing theunpigmented primer and the fully formulated primer are the same in kindand quantity as in Example XI.

    ______________________________________                                        Materials     Parts by Weight                                                 ______________________________________                                        Epon 1001.sup.(1)                                                                           50                                                              ______________________________________                                         .sup.(1) See Example II, a product of Shell Chemical Company.            

Unphosphated steel panels coated with the fully formulated primerdisplay excellent corrosion resistance, good xylene solvent resistanceand flexibility.

EXAMPLE XV

This example illustrates that high levels of alkanol amines are requiredfor good coating properties for the multicomponent system. In thisexample poor corrosion resistance of a primer coating is observed whentoo high a level of a secondary alkyl amine is incorporated into theprimer formulation.

    ______________________________________                                        Part A                                                                        Preparation of Unpigmented Primer                                             Materials             Parts by Weight                                         ______________________________________                                        Epon 828.sup.(1)      34                                                      Triethylene Glycol    19.4                                                    Ethanolamine          6.1                                                     Diethylamine          7.3                                                     Butylated Melamine resin (RN602).sup.(2)                                                            39                                                      Xylene                30                                                      ______________________________________                                         .sup.(1) See Example III, a product of Shell Chemical Company.                .sup.(2) See Example I, a product of Mobil Chemical Company.             

The unpigmented primer is prepared by combining the epoxy resin, thetriethylene glycol, the ethanolamine, the diethylamine and butylatedmelamine in xylene. Once homogeneous, the material in part A above ispigmented in the manner described in Example XIB. The fully formulatedprimer is applied to cold rolled, unphosphated steel panels and baked at180° C. for 20 minutes. The coating which resulted was notsatisfactorily cured.

EXAMPLE XVI

This example illustrates that primers with poor corrosion resistance areobtained if the epoxy resin is reacted with only primary alkanolamineand glycol prior to formulation of the primer.

    ______________________________________                                        Materials             Parts by Weight                                         ______________________________________                                        Epon 828.sup.(1)      34                                                      Triethylene glycol    19.4                                                    Ethanolamine          12.2                                                    Butylated melamine resin (RN602).sup.(2)                                                            39                                                      Xylene                30                                                      Methyl ethyl ketone   25                                                      Butanol               40                                                      Reactor Charge                                                                Epon 828.sup.(1)      34                                                      Triethylene glycol    19.4                                                    Ethanol amine         12.2                                                    Methyl ethyl ketone   12                                                      ______________________________________                                         .sup.(1) See Example III, a product of Shell Chemical Company.                .sup.(2) See Example I, a product of Mobil Chemical Company.             

The reactor charge is stirred in a reaction vessel equipped with astirrer, reflux condenser and thermometer. The solution is initiallyclear and of low viscosity. Within 5-10 minutes of stirring, andexothermic reaction begins, and after 11/2 hours the temperature risesspontaneously to 60° C. After cooling to room temperature the reactorcharge consists of a very viscous material which is subsequently dilutedwith butanol and xylene. The butylated melamine is added and thematerial is pigmented in the manner described in Example XIB. The fullyformulated primer is applied to steel panels and cured in the mannerpreviously described. The resulting coating has very poor corrosionresistance.

EXAMPLE XVII

This example illustrates that the multicomponent primer should be agedfor a certain period of time prior to application to metal panels. Thisexample describes a variation of Example XI which affords coatings withpoor corrosion resistance.

    ______________________________________                                        Part A                                                                        Preparation of Pigmented Component                                            Materials         Parts by Weight                                             ______________________________________                                        Epon 828.sup.(1)  34                                                          Triethylene Glycol                                                                              19.4                                                        Butylated melamine resin.sup.(2)                                                                39                                                          Pigments from Example IB                                                                        39.5                                                        Xylene            10                                                          ______________________________________                                         .sup.(1) See Example III, a product of Shell Chemical Company.                .sup.(2) See Example I, a product of Mobil Chemical Company.             

A pigmented component is prepared by thoroughly dispersing the pigmentsin the epoxy resin, triethylene glycol and the melamine. This pigmentedcomponent is stable for three months at room temperature.

    ______________________________________                                        Part B                                                                        Two Component Primer System                                                   Materials            Parts by Weight                                          ______________________________________                                        Pigmented Component from Part A                                                                    141.9                                                    Ethanolamine         12.2                                                     ______________________________________                                    

A sprayable primer is obtained by thoroughly mixing the pigmentedcomponent from part A with the ethanolamine. The resulting primer issprayed within 10 minutes and cured at 180° for 20 minutes. Theresulting coating has poor corrosion resistance.

EXAMPLE XVIII

The procedures of Example XXVII are followed except that after additionof the ethanol amine the primer formulation is vigorously stirred for 45minutes and then applied by spraying and cured at 180° C. for 20minutes. The coating exhibits good corrosion resistance.

EXAMPLE XIX

The procedures of Example XI are followed except that hydrogenatedbis-phenol A is used in place of the triethylene glycol and satisfactoryprimer compositions are obtained.

EXAMPLE XX

The procedures of Example XI and XII are followed except that thefollowing amino resin crosslinking agent is employed in place of thebutylated melamine to form two other primer compositions: a glycol urilresin that is Cymel 1170 (a product of American Cyanamide). In each casea satisfactory primer composition is obtained upon inclusion of anequivalent amount of the identified amino crosslinking agent.

EXAMPLE XXI

A heat curable water-based coating composition suitable for automotiveapplication is prepared from epoxy-amine reaction product and aminoresin crosslinking agent in the manner as hereinafter set forth:

    ______________________________________                                        Part A                                                                        Preparation of epoxy alkanol amine reaction product                           Materials       Parts by Weight                                               ______________________________________                                        Epon 1004.sup.(1)                                                                             405.27                                                        Diethanol amine 45.41                                                         Propasol P.sup.(2)                                                                            299.31                                                        ______________________________________                                         .sup.(1) See Example I, a product of Shell Chemical Company.                  .sup.(2) A product of Union Carbide Corporation  propylene glycol             monopropylether.                                                         

The reactor charge is heated to 80°-85° C. in a reaction vessel equippedwith a stirrer, reflux condenser and thermometer. The Epon 1004 is addedover a 2 hour period. The temperature is maintained at 80°-85° C.throughout the addition and for 16 hours thereafter. The epoxy alkanolamine reaction product so formed is then cooled to room temperature andformulated into a water-based primer as hereinafter described:

    ______________________________________                                        Part B                                                                        Preparation of Millbase                                                       Materials              Parts by Weight                                        ______________________________________                                        Epoxy alkanol amine reaction product                                                                 160.00                                                 from Part A                                                                   Propasol P             41.04                                                  Barytes pigment        115.64                                                 Titanium dioxide pigment                                                                             15.84                                                  Iron oxide             15.84                                                  Silica                 11.08                                                  ______________________________________                                    

To 160 parts of the epoxy alkanol amine reaction product, 41.04 parts ofPropasol P is added and then shaken for 30 minutes. A homogeneoussolution is obtained. To this then the pigments as shown above are addedand then shaken for 6 hours. A Hegmann gauge reading of 6 to 7 isobtained. This is then used for preparation of fully formulatedpigmented primer.

    ______________________________________                                        Fully Formulated Water-Based Primer                                           Materials             Parts by Weight                                         ______________________________________                                        Millbase from Part B  79.6                                                    Butylated melamine resin (RN602).sup.(1)                                                            2.4                                                     Acetic acid           1.04                                                    KR-55.sup.(2)         0.40                                                    Water (distilled)     69.30                                                   ______________________________________                                         .sup.(1) See Example I, a product of Mobil Chemical Company.                  .sup.(2) KenReact TTMDTP55 titanate coupling agent that is said to be         tetra (2,2diallyloxymethyl-1-butoxy) titanium di (ditridecyl) phosphite,      product of Kenrich Petrochemicals, N.J.                                  

The mill base is weighed into a stainless steel container. To thismillbase the melamine resin is added and stirred well using adisperator. Then the KR-55 coupling agent is added and mixed well. Theacetic acid is weighed into 10 parts of water in a glass container andthen added to the millbase, melamine resin and KR-55 mixture understirring. The balance of water is then added in 10-15 minutes undervigorous stirring. The whole mixing is accomplished in 15-20 minutes.The resulting fully formulated primer is filtered, applied to coldrolled, unphosphated steel panels by spraying and cured at 180° C. for20 minutes. The cured coating displays excellent corrosion resistance insalt spray, good solvent resistance to xylene and good flexibility andhardness.

EXAMPLE XXII

The procedures of Example XXI are repeated except for the followingdifference: The KR-55 coupling agent is replaced by coupling agentKR-238S.sup.(1) at an equal weight level with all other materials beingthe same in kind and quantity.

Unphosphated sheet panels coated with the pigmented primer of thisexample display excellent corrosion resistance to salt spray, goodxylene solvent resistance, flexibility and hardness.

EXAMPLE XXIII

The procedures of Example XXI are repeated except for the followingdifference: The titanate coupling agent KR-55 is replaced by the hydroxyphosphate of Example IX (b) and the level of melamine resin is increasedto 4.8 parts by weight. All ether materials are the same in kind andquantity in Example XXI.

Unphosphated steel panels coated with the fully pigmented primer displayexcellent corrosion resistance, good xylene resistance, flexibility andhardness.

EXAMPLE XXIV

The procedures for Example XXI are repeated with the followingdifferences: The millbase is prepared with 30.5 parts of Propasol Pinstead of 41.04 parts and the fully pigmented primer contained higherlevel of water. The ingredients remain the same in kind.

    ______________________________________                                        Part B                                                                        Preparation of Millbase                                                       Materials              Parts by Weight                                        ______________________________________                                        Epoxy - alkanol amine reaction product                                                               160.00                                                 from Part A, Example XXI                                                      Propasol P.sup.(1)     30.50                                                  Barytes                115.64                                                 Titanium dioxide       15.84                                                  Iron oxide             15.84                                                  Silica                 11.08                                                  ______________________________________                                         .sup.(1) See Example XXI, a product of Union Carbide Corporation.        

It is mixed as in Part B, Example XXI.

    ______________________________________                                        Fully Formulated Primer                                                       Materials         Parts by Weight                                             ______________________________________                                        Millbase from Part B                                                                            87.2                                                        Melamine resin (RN602).sup.(2)                                                                  2.4                                                         Acetic acid       1.39                                                        KR-55.sup.(3)     0.40                                                        Water             94.40                                                       ______________________________________                                         .sup.(2) See Example I, a product of Mobil Oil Chemical Company.              .sup.(3) See Exmaple XXI, Titanate coupling agent.                       

Unphosphated steel panels coated with the fully pigmented primer displayexcellent corrosion resistance to salt spray, good xylene solventresistance, flexibility and hardness.

EXAMPLE XXV

The procedures for Example XXIV are repeated with the followingdifference: Titanate coupling agent is replaced by titanate couplingagent KR-238S (Ken-React a product of Kenrich Petrochemicals and is saidto be di(dioctylpyrophosphato) ethylenetitanate). All other materialsused in preparing the epoxy alkanol amine resin and the fully formulatedprimer are same in kind and quantity as in Example XXIV.

    ______________________________________                                        Materials     Parts by Weight                                                 ______________________________________                                        KR-238S.sup.(1)                                                                             0.4                                                             ______________________________________                                    

Unphosphated steel panels combed with the fully pigmented primer displayexcellent corrosion resistance to salt spray, good xylene solventresistance, flexibility and hardness.

EXAMPLE XXVI

The procedures of Example XXIV are repeated with the followingdifference: Titanate coupling agent KR-55 is replaced by hydroxyphosphate and the level of the melamine resin is increased. All othermaterials used in preparing the epoxy-alkanol amine resin and the fullyformulated primer are the same in kind and quantity as in Example XXI.

    ______________________________________                                        Materials             Parts by Weight                                         ______________________________________                                        Hydroxy phosphate.sup.(1)                                                                           0.24                                                    Butylated melamine resin (RN602)                                                                    4.80                                                    ______________________________________                                         .sup.(1) Made in accordance with Example IX(b).                               .sup.(2) A product of Mobil Chemical Company, see Example I.             

Unphosphated steel panels coated with the fully pigmented primer displayexcellent corrosion resistance to salt spray, good xylene solventresistance, flexibility and hardness.

EXAMPLE XXVII

(a) A heat curable water based coating composition suitable forautomotive application is prepared from a bis-phenol A epichlorohydrinepoxy resin, alkanol amine and an amino resin crosslinking agent in themanner hereinafter set forth:

    ______________________________________                                        Part A                                                                        Preparation of epoxy alkanol amine resin                                      Materials      Parts by Weight                                                ______________________________________                                        Epon 1004.sup.(1)                                                                            312.34                                                         Diethanolamine  35.00                                                         Propasol P.sup.(2)                                                                           230.68                                                         ______________________________________                                         .sup.(1) See Example I, a product of Shell Chemical Company.                  .sup.(2) See Example XXI, a product of Union Carbide Corporation.        

To the mixture of diethanol amine and Propasol P in a 3-necked flaskequipped with reflux condenser and thermometer, Epon 1004 was added insmall portions over a period of 2 hours at a reflux temperature of95°-100° C. It was then refluxed for another 18 hours at thattemperature.

    ______________________________________                                        Part B                                                                        Formulation of Primer                                                         Materials           Parts by Weight                                           ______________________________________                                        Epoxy-alkanol amine resin from                                                Part A              40.00                                                     Melamine resin (RN602)                                                                            4.80                                                      Propasol P          16.30                                                     Titanium dioxide pigment                                                                          4.40                                                      Iron oxide pigment  4.40                                                      Silica pigment      3.08                                                      Barytes pigment     32.40                                                     Glacial acetic acid 1.04                                                      Distilled water     73.94                                                     ______________________________________                                    

Preparation of the Millbase

To one-third (13.3 parts) or the epoxy alkanol amine resin is added,one-third (1.60 parts) of the melamine resin followed by all of (16.30parts) of Propasol P; pigments are dispersed in this mixture by ballmilling.

Preparation of the Complete Primer

To the millbase is added the balance (26.7 parts) of the epoxy alkanolamine resin is added followed by the balance (3.2 parts) of thebutylated melamine resin. Then, 1.04 parts of glacial acetic acid, theamount required to achieve 75% neutralization of the epoxy alkanol amineresin, in 10 parts of distilled water is added slowly with stirring. Thebalance of the water is then added gradually under vigorous stirringover a period of 5 minutes. The resulting fully formulated primer isfiltered, applied to cold rolled, unphosphated steel panels by sprayingand cured at 180° C. for 20 minutes. The cured coating displaysexcellent corrosion resistance in salt spray, good solvent resistance toxylene and good flexibility and hardness.

(b) Following the procedures of Example XXVII(a), the melamine resin(RN602) is replaced by the same parts by weight of LTX-127 (a product ofMonsanto which is a partially methylated melamine) and equivalent filmproperties are achieved and the fully formulated primer exhibitssuperior dispersion stability as compared to the primer of (a).

(c) Following the procedures of Example XXVII(a), the melamine resin(RN602) is replaced by equal parts by weight of Cymel 1141 (a product ofAmerican Cyanamide) and equivalent film properties are obtained and thefully formulated primer exhibits superior dispersion stability ascompared to the primer of (a).

What is claimed is:
 1. A water dilutable primer concentrate thatprovides upon intimate admixture with water a primer composition whichretards corrosion even in substantial absence of chromate corrosioninhibiting pigments and which comprises an intimate admixture of filmforming ingredients which consist essentially of:(A) A substantially gelfree epoxy and amine reaction product which contains no ester linkagesand which is made by reacting in non-aqueous water miscible mediumreactants consisting essentially of:
 1. An epoxy reactant having two1,2-epoxy groups per molecule which is the reaction product of bisphenolA and epichlorohydrin and has an epoxide equivalent weight range from atleast about 875 to 4,000; and2. A water soluble amine reactant selectedfrom the group consisting of secondary monoamines having a total of upto about 20 carbons, and comprising at least about 90 mole percentsecondary hydroxy amine that has two or more alkyl groups each bearing aprimary hydroxy group in a stoichiometric amount such that the reactionproduct (A) comprises tertiary amino and primary and secondary hydroxygroups and is substantially free of unreacted epoxy groups; (B) An aminoaldehyde resin crosslinking agent at about 5-30% by weight of A; and (C)Non-chromate pigment at a weight ratio of A+B+C of about 40:60 to 60:40,wherein a mixture of A, B, and C is neutralized at least partially withD a weak organic acid.
 2. The primer concentrate in accordance withclaim 1, wherein the amine reactant is a dialkanol amine having up toabout 10 carbons.
 3. The primer concentrate in accordance with claim 1or 2, wherein the amino aldehyde crosslinking agent comprises alkylatedmelamine resin.
 4. The primer concentrate in accordance with claim 3,wherein the water miscible medium comprises a compound selected fromR(OC_(x))_(y) -OH wherein R is C₁ -C₈ alkyl, X is 2-4, and y is 1-10which boils below about 180° C.
 5. The primer concentrate in accordancewith claim 4, wherein the acid is selected from any of formic, acetic oroxalic acids.